Of all the improvements made this winter, by far the biggest and hardest in the list was increasing the ground clearance. But, I have to say...it freakin worked. Now the bottom of the box is just about level with the bottom of the trucks. I nearly doubled the clearance from 1.5" to 3". Riding on this box for a few weeks now, i've yet to bottom out on anything.

In order to accomplish this, I literally had to disassemble to motor controller, hack .5" off of the main terminals, drill new holes and get special low profile bolts. Then, because the tolerances were so tight, I printed an ABS plastic spacer that fits in the small gap between the controller and the box walls so it wouldn't short out with a sudden slip or bang.

But before I did all that I had to explore all the options with what I had. I disassemble the battery pack to see what was in there....I tried gaining clearance by splitting the pack into 2 halves, but there was not much to gain. I was able to tweak how the main leads came out of the pack.

Okay, so I decided how it's gonna go - now how the heck was I gonna build it? It seemed expensive and kinda dumb to sub this out to a shop, so I bought a bending brake for $75, and a sheet of aluminum off amazon supply (free shipping with prime :))

As shown in the pictures, I drafted my flat pattern, cut it out, bent it and then riveted it together. In the end flanges, I managed to have Steve install rivnuts so I wouldn't need to have access inside to box to the nut. Just 4 bolts. This was a very nice addition to the design and makes it a breeze to disassemble, service or reprogram.

Now it was time to get everything into place. I knew that the battery and controller were roughly fixed, but I hadn't worked out the rest of the wires and components. They were small details...Enter the wonders of 3D printing. It was super easy to layout all my parts and make everything I needed to get all the little parts right where I wanted them.

The picture should show the rest of the details: charging port, on/off, LEDs.

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